Scope of CFD analysis
This shoe manufacturing facility spans an area of approximately 14,000 square meters. The anticipated thermal load generated by machinery, lighting, other equipment, and personnel within the factory is estimated to be around 900 kilowatts. The project involves analyzing the internal air circulation under both natural and forced convection conditions through Computational Fluid Dynamics (CFD) analysis. The ventilation system is comprised of propeller fans, exhaust fans, windows, and doors. The project scope includes the creation of a 3D CAD model based on the 2D drawings provided by the client, the generation of a CFD mesh, and the execution of CFD analysis for both natural and forced convection scenarios. The CFD analysis will identify flow dead zones, thermal hotspots, and areas requiring enhancement from a thermal comfort standpoint, and will illustrate the necessary modifications through a revised CFD analysis model.
CFD model development
A 3D CAD model is developed using PTC Creo software based on the AutoCAD drawings provided by the Client. The Rivet Architectural model is also referred to during the modelling process to ensure consistency in the building geometry, architectural layout, and relevant structural details. The developed 3D CAD model is reviewed and submitted to the Client for approval. Upon receiving the Client’s approval, the model is used for Computational Fluid Dynamics (CFD) pre-processing, including computational domain preparation and mesh generation, followed by CFD analysis to evaluate airflow patterns, air velocity distribution, temperature distribution, and overall ventilation performance within the facility.
CAD Model Simplified for CFD analysis
The 3D CAD model is simplified, wherever necessary, by removing non-essential geometric details that do not significantly influence the airflow patterns, heat transfer characteristics, or other relevant physical phenomena under investigation. The simplification process is carried out while preserving the key geometrical features and boundary details required for accurate representation of the physical system. Particular attention is given to maintaining suitable geometric quality to facilitate effective CFD meshing, minimize mesh distortion, and achieve an appropriate balance between computational accuracy and simulation cost. These measures help improve numerical stability and promote faster convergence of the CFD solution. All model simplification activities are carried out in consultation with the Client, taking into consideration the project requirements and intended simulation objectives. The proposed modifications are reviewed and the necessary approval is obtained from the Client before proceeding with subsequent CFD pre-processing and analysis activities.
CFD mesh
The CFD mesh is generated for the simplified 3D CAD model described in the previous section. A Poly-Hexcore mesh approach is adopted to achieve an effective balance between computational accuracy and computational efficiency. The mesh is designed to adequately capture the overall geometry and airflow characteristics of the facility, with appropriate local refinement in regions where significant variations in flow parameters are expected, such as around the fans, ventilation ducts, and other critical airflow passages. This refinement helps resolve local velocity gradients and complex flow behaviour, thereby improving the accuracy of the simulation results. The computational mesh comprises approximately 35 million cells, with suitable mesh quality metrics maintained to ensure numerical stability and solution accuracy. The mesh quality is assessed to minimize potential numerical errors and support stable convergence during the CFD solution process. The resulting mesh provides an appropriate level of spatial resolution to evaluate airflow distribution, velocity variations, temperature distribution, and overall ventilation performance within the facility.
CFD analysis results - Velocity Field
A comprehensive evaluation of the velocity field obtained from the CFD analysis was carried out to understand the airflow distribution and identify regions with inadequate air circulation within the facility. The velocity contours and flow patterns were examined to locate potential dead zones, characterized by low air velocity, stagnant airflow, or insufficient air movement. These regions were assessed to determine the effectiveness of the existing ventilation arrangement and identify areas requiring improvement. Based on the findings, suitable corrective measures were proposed to improve airflow circulation and minimize stagnant zones throughout the facility. The CFD results also provided valuable insights into the effectiveness of the existing fan arrangement, enabling the optimization of fan locations, mounting positions, and directional orientations. These modifications were aimed at improving air distribution, enhancing the penetration of airflow into poorly ventilated areas, and promoting more uniform ventilation throughout the workspace. The effectiveness of the proposed modifications was subsequently evaluated through CFD simulations to assess the resulting improvements in airflow patterns and overall ventilation performance.
CFD analysis results - Temperature Field
A thorough evaluation of the temperature distribution obtained from the CFD analysis was carried out to identify thermal hotspots and regions experiencing elevated temperatures within the factory area. The temperature contours were examined to understand the spatial variation in temperature and assess the effectiveness of the existing ventilation system in removing accumulated heat. Particular attention was given to areas where elevated temperatures could be attributed to inadequate airflow, heat accumulation, or insufficient ventilation. Based on the findings, appropriate corrective measures were recommended to mitigate the identified thermal hotspots and improve heat dissipation throughout the facility. These measures were aimed at enhancing air circulation, facilitating the effective removal of accumulated heat, and achieving a more uniform temperature distribution within the factory. The effectiveness of the proposed modifications was subsequently assessed through CFD simulations to evaluate the resulting improvements in thermal conditions and overall ventilation performance.
Conclusions drawn from CFD analysis
The CFD analysis enabled the identification of regions with stagnant or inadequate airflow, as well as thermal hotspots within the factory area. The simulation results, including velocity and temperature contours, were thoroughly evaluated to understand the underlying causes of poor air circulation and localized heat accumulation. Based on these findings, suitable corrective measures were proposed and discussed with the Client to address the identified ventilation and thermal management issues. In consultation with the Client, the necessary modifications were implemented, which included optimizing fan placement and directional orientation, wherever required, to improve airflow distribution and enhance heat removal from critical areas. Following the implementation of these corrective measures, a subsequent CFD analysis was carried out to assess their effectiveness. The results of the revised simulation were compared with those of the baseline analysis to evaluate improvements in airflow patterns, reduction of stagnant zones, mitigation of thermal hotspots, and overall temperature distribution within the facility. This comparative assessment provided a quantitative basis for evaluating the effectiveness of the implemented measures and determining the extent of improvement in the overall ventilation performance.
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